EP0774527A2 - Matériau composite extra-dur et son procédé de préparation - Google Patents

Matériau composite extra-dur et son procédé de préparation Download PDF

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Publication number
EP0774527A2
EP0774527A2 EP96118298A EP96118298A EP0774527A2 EP 0774527 A2 EP0774527 A2 EP 0774527A2 EP 96118298 A EP96118298 A EP 96118298A EP 96118298 A EP96118298 A EP 96118298A EP 0774527 A2 EP0774527 A2 EP 0774527A2
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European Patent Office
Prior art keywords
composite member
accordance
superhard composite
diamond
sintering
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EP96118298A
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German (de)
English (en)
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EP0774527A3 (fr
EP0774527B1 (fr
Inventor
Hideki C/O Sumitomo Elec. Ind. Ltd. Moriguchi
Yoshifumi C/O Sumitomo Elec. Ind. Ltd. Arisawa
Michio C/O Sumitomo Elec. Ind. Ltd. Otsuka
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Sumitomo Electric Industries Ltd
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Sumitomo Electric Industries Ltd
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Priority to EP00102888A priority Critical patent/EP1028171B1/fr
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Publication of EP0774527A3 publication Critical patent/EP0774527A3/fr
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/06—Metallic powder characterised by the shape of the particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12—Both compacting and sintering
    • B22F3/14—Both compacting and sintering simultaneously
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B41/00—Component parts such as frames, beds, carriages, headstocks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D99/00—Subject matter not provided for in other groups of this subclass
    • B24D99/005—Segments of abrasive wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
    • B22F2009/041—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling by mechanical alloying, e.g. blending, milling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12014—All metal or with adjacent metals having metal particles
    • Y10T428/12028—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
    • Y10T428/12049—Nonmetal component
    • Y10T428/12056—Entirely inorganic

Definitions

  • the present invention relates to a superhard composite member consisting of a sintered body of cemented carbide or the like which is composited with diamond grains, and a method of manufacturing the same.
  • Japanese Patent Laying-Open No. 7-34157 (1995) discloses a technique of sintering the material under thermodynamically instable pressure and temperature conditions for diamond in a solid phase thereby preparing a diamond composite member without employing an ultra high-pressure vessel, as one of proposals for solving the aforementioned problem.
  • Japanese Patent Laying-Open No. 6-287076 (1994) discloses a technique of direct resistance heating and pressurized sintering an inclination functional member having an inclination mixed layer consisting of a metal and ceramics between members of the metal and the ceramics with a molding outer frame and upper and lower push rods.
  • the molding outer frame serving as one of electrical paths is varied in thickness thereby forming a temperature gradient which is responsive to an inclined composition.
  • inclination mixed layer indicates a layer having an inclined composition, i.e., a concentration gradient (composition change) of the components.
  • U.S. Patent No. 5,096,465 discloses a technique of preparing a composite member holding metal-coated superhard grains of diamond or CBN in a binder phase by infiltration.
  • the material is sintered in a solid phase, and hence bonding strength between the diamond and a metal binder is so insufficient that the diamond may be dropped out.
  • the prior art 2 is not directed to a diamond composite member, dissimilarly to the present invention.
  • the diamond variance depends on the grain sizes of the added diamond, i.e., the packing density of the diamond grains, and hence it is difficult to prepare a composite member having an arbitrary diamond variance with arbitrary diamond grain sizes. Further, it is difficult to prepare a dense composite member by the infiltration, and this disadvantage is particularly remarkable in a large-sized or heteromorphic member.
  • An object of the present invention is to provide a superhard composite member having a sufficient dense and homogeneous structure which can be manufactured without employing an ultra high-pressure vessel, and a method of manufacturing the same.
  • the inventive composite member is adapted to attain the aforementioned object, and contains a hard phase of at least one element selected from a group of WC, TiC, TiN and Ti(C, N) a binder phase consisting of an iron family metal and diamond grains, which are formed by direct resistance heating and pressurized sintering.
  • the inventive composite member is a sintered body, holding diamond grains in a matrix of cemented carbide or cermet in a dispersed state, which is obtained by direct resistance heating and pressurized sintering.
  • a member composited with diamond grains is preferably prepared from a hard phase of WC cemented carbide, i.e., WC, and a binder phase of Co or Ni.
  • the binder phase is preferably prepared from an iron family metal such as Co, Ni, Cr or Fe.
  • the inventive composite member may contain unavoidable impurities, as a matter of course. Examples of the unavoidable impurities are Al, Ba, Ca, Cu, Fe, Mg, Mn, Ni, Si, Sr, S, O, N, Mo, Sn, Cr and the like.
  • the direct resistance heating and pressurized sintering can be completed in a short time within 10 minutes since the sintered material can be rapidly heated, pressurized and cooled by resistance heating without employing an external heater. Therefore, the time for exposing the sintered material to a high temperature can be reduced as compared with the case of merely reducing the maximum temperature holding time in conventional pressure sintering, so that the sintering can be ended with no transformation of diamond to graphite. Further, the bonding strength between diamond and the matrix can be increased by the direct resistance heating and pressurized process, although the reason for this has not yet been clarified. In addition, it is also possible to accelerate the sintering by generating plasma between the grains through a pulse current.
  • inventive composite member which has been impossible to attain through the conventional pressure sintering, can be attained by the direct resistance heating and pressurized sintering. Further, the inventive composite member can be manufactured in a short-time cycle, whereby cost reduction can be expected due to improvement in the rate of operation of equipment.
  • inventive composite member preferably comprises the following factors independently of or in combination with each other:
  • a dense sintered body can be prepared at a low temperature in a short time within 10 minutes due to the direct resistance heating and pressurized sintering to be capable of preventing quality deterioration of CBN or the like and suppressing reaction on the interface, whereby a superhard composite member which is superior in characteristic to the prior art can be manufactured.
  • a composite material according to the present invention contains at least one hard phase selected from a group consisting of WC, TiC and TiN, a binder phase mainly composed of an iron family metal, and a plurality of diamond grains dispersed in a structure having the hard phase and the binder phase, and comprises at least one of the following structures:
  • the composite material having the aforementioned structure includes that obtained by direct resistance heating and pressurized sintering as a matter of course, and that manufactured by another method.
  • inventive composite material is preferably employed as a cutter bit for a shield machine.
  • the shield machine In tunnel work or the like, the shield machine must continuously excavate portions between shafts without exchanging the cutter bit. Therefore, the cutter bit must not be chipped during excavation.
  • considerably hard cemented carbide is employed (refer to Japanese Patent Laying-Open No. 7-269293 (1995)) or the number of such cutter bits is increased (refer to Japanese Patent Laying-Open No. 6-74698 (1994)).
  • the hard cemented carbide is readily reduced in toughness, and hence chipping is unavoidable.
  • increase of the bit number leads to a high cost. While the distance for continuous excavation can be reduced by increasing the number of shafts, this leads to increase of the term of works or the cost. If the number of shafts is increased on the bottom of the sea or a river, the cost is extremely increased.
  • the inventive superhard composite material which has both of excellent wear resistance of diamond and excellent toughness of cemented carbide can stably perform long-distance excavation, to exhibit remarkably excellent characteristics as a cutter bit material for a shield machine. Further, the inventive superhard composite material can be manufactured at a low cost without through the conventional process employing an ultra high-pressure vessel.
  • a superhard composite member comprises a hard phase mainly composed of WC, a binder phase mainly composed of Co, and a plurality of diamond grains dispersed in a structure having the hard phase and the binder phase, and comprises all of the following factors:
  • a sintered body comprising a hard phase mainly composed of WC, a binder phase mainly composed of Co and a plurality of diamond grains dispersed in a structure having the hard phase and the binder phase is obtained by low-temperature sintering, and hence no dense sintered body can be manufactured.
  • the apparent porosity of the factor (2) satisfying A00 to A08 and B00 to B08 in ISO standards cannot be attained.
  • the main crystal system of Co is h.c.p., and this sintered body is at an insufficient impact resistance level.
  • a superhard composite member comprising a hard phase mainly composed of WC, a binder phase mainly composed of Co and a plurality of diamond grains dispersed in a structure having the hard phase and the binder phase along with all of the factors (1) to (4) has superior characteristics as compared with the conventional member. While a direct resistance heating and pressurized method is preferably employed as a method of manufacturing this member, the present invention is not restricted to this method.
  • a method of manufacturing the aforementioned composite member comprises the steps of mixing raw powder materials including diamond powder, hard phase powder and a binder phase with each other for obtaining a mixed raw material, and directly resistance heating the mixed raw material with application of prescribed pressure for heating the mixed raw material to a prescribed temperature and sintering the same.
  • the prescribed temperature is preferably at least 1100°C and not more than 1350°C
  • the prescribed pressure is preferably at least 5 MPa and not more than 200 MPa. More preferably, the prescribed pressure is at least 10 MPa and not more than 50 MPa, in order to enable employment of a low-priced graphite mold.
  • diamond grains or the like may be provided with the aforementioned outer and/or inner coatings by well-known plating, CVD or PVD.
  • mechanical alloying is preferably employed. Due to employment of the mechanical alloying, the hard phase powder is coated with the binder phase powder, whereby the sintering property is improved to facilitate densification.
  • a step of introducing the mixed raw material into a resistance heating apparatus for direct resistance heating and pressurized sintering includes a step of introducing the mixed powder into the resistance heating apparatus as such as a matter of course, or a step of introducing a previously pressed green compact, an intermediate sintered body, or a laminate.
  • a composite which is prepared by arranging the mixed raw material on the substrate may be introduced into the resistance heating apparatus.
  • sintering temperature indicates the temperature on a surface of a graphite mold at the time of controlling the amount of a current of a sintering apparatus. The actual sample temperature is conceivably higher than this temperature by 200 to 300°C. It is difficult to increase the pressure beyond 200 MPa in equipment, and this leads to a high cost.
  • the sintering time is preferably within 10 minutes. More preferably, the sintering time is within 3 minutes.
  • the binder phase of cemented carbide is dissolved to form a liquid phase, and dissolves diamond which in turn is readily deposited as carbon.
  • this reaction requires a long time, and hence transformation of diamond to carbon can be suppressed to the utmost by setting the liquid phase formation time within 10 minutes.
  • a plurality of types of mixed raw materials having different mixing ratios of diamond powder may be prepared in the step of obtaining the mixed raw material. These plurality of types of mixed raw materials are stacked in order of the diamond powder mixing ratios in the step of sintering the materials.
  • a composite member having a composition which is stepwisely varied in the thickness direction can be obtained if the number of the types of the raw materials having different diamond powder mixing ratios is small, while a composite member having a substantially continuously varied composition can be obtained if the number of the types of the raw materials is large and the stacked layers are reduced in thickness.
  • a portion of the composite member which is close to the bonding surface may contain absolutely no diamond grains.
  • each dried powder was charged in a graphite mold, which in turn was so energized that the programming rate was 250°C/min. with application of pressure of 20 MPa from above and below in a vacuum of not more than about 0.01 Torr, and kept at a temperature of 1150°C for 2 minutes for sintering (the so-called resistance heating and pressurized sintering), and thereafter the powder was quenched.
  • the obtained sintered bodies of 20 mm in diameter and 5 mm in thickness were observed, to find no cracks on the samples. Further, the samples were surface-ground and the ground surfaces were observed with an optical microscope of 200 magnifications, to find no pores on the samples.
  • a sintered body was prepared by a conventional method under conditions of 1350°C, 1 hour and keeping in a vacuum.
  • This comparative sample and the sintered body of the sample No. 1-4 were surface-ground and mirror-polished, and thereafter the structures thereof were photographed.
  • Figs. 2A and 2B deterioration conceivably resulting from graphitization is observed on the interface between diamond appearing black and WC as shown in Fig. 2N, and diamond itself is damaged by cracking etc.
  • neither deterioration nor damage is observed on the sintered body of the sample No. 1-4, as shown in Fig. 2A.
  • a sample No. 2-1 was prepared in the same composition as the sample No. 1-4 of Test Example 1 except that only the direct resistance heating and pressurized sintering conditions were changed to a temperature of 1250°C and a programming rate of 200°C/min. for generating a liquid phase and quenching the material with no keeping.
  • the obtained sintered body was surface-ground with a grinding stone of #400, and finished into a disc of 20 mm in diameter and 5 mm in thickness.
  • This sintered body was sandblasted with SiC of 200 ⁇ m in mean grain size at 5 kg/cm 2 for 30 minutes for investigating the weight reduction ratio of the sintered body, which was 0.05 %.
  • the sintered body of the sample No. 1-4 was similarly sandblasted, to find that its weight reduction ratio was 0.3 %.
  • the sample No. 2-1 was by far superior in wear resistance.
  • a sintered body of a sample No. 3-1 was prepared in the same composition as the sample No. 1-7 of Test Example 1 under conditions of a temperature of 1600°C and pressure of 6 GPa with an ultra high-pressure vessel.
  • the sintered bodies of the samples Nos. 1-7 and 3-1 were dipped in aqua regia for dissolving Co and Ni. Consequently, the sample No. 1-7 was pulverized while the sample No. 3-1 exhibited substantially no shape change.
  • a sintered body of a sample No. 4-1 was prepared in the same composition as the sample No. 1-4 similarly to Test Example 3, under conditions of a temperature of 1600°C and pressure of 6 GPa with an ultra high-pressure vessel.
  • the sintered bodies of the samples Nos. 1-4 and 4-1 were surface-ground so that the ground surfaces were mirror-polished with diamond paste, and the polished surfaces were observed with an SEM and a TEM.
  • Samples Nos. 5-1 to 5-6 were prepared basically in the same composition as the sample No. 1-4 under the same sintering conditions as Test Example 2 while varying only diamond contents as shown in Table 2. Thus, the sample No. 5-4 was identical to the sample No. 2-1. Table 2 Sample No. Diamond WC Co Weight Reduction Ratio Transverse Rupture Strength 5-1 0 73.3 26.7 0.50% 2.5GPa 5-2 5 69.7 25.3 0.25% 2.1GPa 5-3 15 62.3 22.7 0.18% 1.8GPa 5-4 25 55 20 0.05% 1.5GPa 5-5 50 36.7 13.3 0.21% 0.9GPa 5-6 80 14.7 5.3 0.43% 0.7GPa
  • Table 2 also shows the weight reduction ratios of the sintered bodies along with transverse rupture strength. From the results shown in Table 2, it is understood that superior erosion resistance is attained when the content of diamond grains is in the range of 5 to 50 vol.%.
  • Samples Nos. 5-4 and 6-1 to 6-5 were prepared in the same composition as the sample No. 1-4 under the same sintering conditions as Test Example 2, while varying only the mean grain sizes of diamond grains as shown in Table 3.
  • Table 3 Sample No. Diamond Grain Size Weight Reduction Ratio Transverse Rupture Strength 5-4 10 ⁇ m 0.05% 1.5GPa 6-1 30 ⁇ m 0.03% 1.4GPa 6-2 100 ⁇ m 0.04% 1.2GPa 6-3 800 ⁇ m 0.05% 1.0GPa 6-4 1500 ⁇ m 0.06% 0.7GPa 6-5 3 ⁇ m 0.14% 1.8GPa ⁇
  • Table 3 also shows the weight reduction ratios and transverse rupture strength of the sintered bodies of the respective samples which were sandblasted similarly to Test Example 2. From the results shown in Table 3, it is understood that particularly superior erosion resistance is attained in the sintered body having average diamond grain diameter of 10 to 1000 ⁇ m.
  • Sintered bodies of samples Nos. 7-1 to 7-4 were prepared by employing powder materials of compositions shown in Table 4 while varying only pressure to 100 MPa in the sintering conditions of Test Example 2.
  • Table 4 Sample No. Diamond Mean Grain Size 20 ⁇ m WC Co Ti Si Cr W Zr Raman Spectral Intensity 7-1 30 55 15 100% 7-2 30 52 15 3 20% 7-3 30 52 15 1 2 15% 7-4 30 52 15 2 1 10%
  • the obtained sintered bodies were mirror-finished and the mirror surfaces were spectrally analyzed by Raman spectroscopy. Consequently, the samples Nos. 7-2 to 7-4 exhibited small peak intensities assuming that the peak intensity of a Raman line of carbon detected in the sample No. 7-1 was 100 %.
  • an element belonging to the group IVa, Va or VIa of the periodic table such as Ti or Cr, or Si.
  • a sample No. 8-1 was prepared similarly to the sample No. 7-1 with further addition of 5 wt.% of carbon for sintering.
  • the samples Nos. 7-1 and 8-1 were mirror-polished, holes conceivably resulting from diamond grains graphitized and dropped out in mirror polishing were partially observed in portions around the diamond grains in the sample No. 7-1.
  • portions around diamond grains were normal and presence of free carbon was confirmed through observation with an optical microscope of 200 magnifications in the sample No. 8-1.
  • the samples Nos. 7-1 and 8-1 were sandblasted similarly to Test Example 2, to recognize that the weight reduction ratio of the sample No. 7-1 was 0.04 % while the sample No. 8-1 had a small weight reduction ratio of 0.02 %. Thus, the sample No. 8-1 was superior in erosion resistance.
  • Samples Nos. 9-1 to 9-6 having compositions shown in Table 5 were prepared under the same sintering conditions as Test Example 2. These samples were sandblasted similarly to Test Example 2, to observe weight reduction ratios shown in Table 5. From these results, it is decided that the content of an iron family metal forming a binder phase is preferably in the range of 10 to 50 vol.%.
  • Table 5 Sample No. Diamond Mean Grain Size 30 ⁇ m WC Co Ni Weight Reduction Ratio 9-1 30 65 3 2 0.51% 9-2 30 60 10 0 0.18% 9-3 30 45 20 5 0.05% 9-4 30 30 30 10 0.09% 9-5 30 20 40 10 0.21% 9-6 30 10 60 0 0.39%
  • Samples Nos. 10-1 to 10-5 were prepared by employing powder materials having the same composition as the sample No. 1-5 in Test Example 1, heating the materials to 1200°C at a programming rate of 100°C/min., keeping the same for times shown in Table 6 for performing direct resistance heating and pressurized sintering, and quenching the materials at 100°C/min.
  • Table 6 also shows specific gravity values of the respective samples. Presence/absence of diamond in the sintered bodies was examined by X-ray diffraction technique, to observe diamond peaks in all samples. Further, the sintered bodies were mirror-polished and thereafter observed with an optical microscope, to find the results shown in Table 6. Thus, it is understood that the holding time at a temperature of at least 1150°C is preferably within 10 minutes. Table 6 Sample No. Keeping Time Holding Time at Temperature exceeding 1150°C Specific Gravity (g/cm 3 ) Diamond Peak in X-Ray Diffraction Apparent Porosity 10-1 0 1 min. 9.91 yes porous (B04) 10-2 1 min. 2 min. 9.99 yes slightly porous (A04) 10-3 2 min. 3 min. 10.05 yes unporous (A02) 10-4 7 min. 8 min. 10.01 yes slightly porous (A02-A04) 10-5 15 min. 16 min. 9.88 yes diamond remarkably dropped
  • a sample No. 11-1 was prepared under the same conditions as the sample No. 10-1 of Test Example 10 while employing diamond powder subjected to electroless plating of Co before sintering. Consequently, the specific gravity was improved to 10.05, and an apparent porosity was confirmed by observation with an optical microscope. Thus, it is understood that the sintered body can be readily densified by employing powder which is prepared by coating diamond powder with Co by plating.
  • Powder materials of the same compositions as the samples Nos. 10-1 to 10-5 of Test Example 10 were dry-blended in a ball mill for 24 hours. A section of the obtained powder was observed with an SEM, to confirm that diamond, WC and TiC were embedded in Co and mechanically alloyed. This powder was employed for preparing a sample No. 12-1 under the same sintering conditions as the sample No. 10-1. Consequently, the specific gravity was improved to 10.04, and annihilation of pores was confirmed by observation with an optical microscope. Thus, it has been understood that the sintered body is readily densified when mechanical alloying is employed for the step of mixing powder materials consisting of diamond, WC, TiC and Co.
  • Powder materials having compositions (vol.%) shown in Table 7 were pressed in layers and charged in a graphite mold, which in turn was supplied with a current so that the programming rate was 200°C/min. with application of pressure of 50 MPa from above and below and kept at a temperature of 1200°C for 1 minute for performing direct resistance heating and pressurized sintering, and thereafter quenched.
  • the obtained discoidal sintered body of 50 mm in diameter and 20 mm in thickness was observed, to find no cracks between the layers, which were excellently bonded with each other.
  • a section of the sintered body along the thickness direction was mirror-polished and its composition was analyzed with an EPMA and an AES, to find that movement of the elements between the respective layers was relatively small and diffusion of the components between the layers, which was disadvantageously in the conventional sintered body, was suppressed.
  • the inventive sintered body has excellent wear resistance due to the diamond contained in the surface layer, while high strength and toughness can be attained due to cemented carbide or steel forming the internal layer.
  • the inventive member can attain compatibility between these characteristics, which generally conflict with each other. Further, this member can extremely advantageously be manufactured at a low cost without employing an ultra high-pressure vessel.
  • Table 7 Diamond WC Co Fe C Thickness of Sintered Body mm First Layer 30 50 20 5 Second Layer 70 30 5 Third Layer 98 2 10
  • each of mixed powder materials 3 having the compositions of Test Example 5 was charged on a spherical end surface 2 of a steel substrate 1 in a pressure heating apparatus, and sintered under the same sintering conditions as Test Example 5 so that each sintered body was sintered/bonded onto the end surface 2 of the substrate 1.
  • the resistance heating apparatus shown in Fig. 3 has a heater 5 of graphite corresponding to the shape of each raw material powder 3 on the substrate 1, and this heater 5 is pressed against the substrate 1 by an upper pressure ram 6, for heating a pressed laminate.
  • a heat insulator 4 of Si 3 N 4 is interposed between the heater 5 and the pressure ram 6. Sintering is performed by energizing the heater 5 by a dc heat source 7.
  • the temperature of the heater 5 is controlled by a thermocouple 8 of Si 3 N 4 .
  • the bottom surface of the substrate 1 is air-cooled.
  • the raw material powder 3 is heated from its surface side, so that a temperature gradient can be formed with a high temperature on the surface side and a low temperature on the bonding interface.
  • the resistance heating apparatus shown in Fig. 3 can suppress temperature rise of the substrate 1, for preventing annealing of quenched steel (substrate).
  • the charged mixed powder 3 may be prepared from only a single layer of the sample No. 5-4 of Test Example 5, or formed in a multilayer structure as shown in Fig. 3 so that the layer which is in contact with the end surface 2, the next layer and the outermost layer are formed by the samples Nos. 5-2, 5-3 and 5-4 respectively.
  • the multilayer structure it is possible to obtain a composite member in such a structure that the outermost layer has high hardness and the remaining layers have high toughness.
  • a sintered body of such a multilayer structure was connected with a substrate in the aforementioned apparatus, whereby the substrate and the sintered body were in excellent connection in addition to bondability of the respective layers.
  • a raw material member 3 and a substrate 1 may be arranged in a carbon outer frame 9 as shown in Fig. 4, so that direct resistance heating and pressurized sintering is made while applying pressure by upper and lower punches 10 and 11 and feeding a pulse current by a pulse source 12.
  • the temperature is controlled by a thermocouple 8.
  • a surface (V surface/V section) of the sample No. 1-4 of Test Example 1 vertical with respect to a pressure axis and a surface (H surface/H section) horizontal with respect to the pressure axis were subjected to X-ray diffraction through a Cu-K ⁇ line.
  • Table 8 shows values of V(001)/V(101) and H(001)/H(101) in the aforementioned case respectively.
  • Table 8 Sample No. V(001) V(101) H(001) H(101) Mean Crystal Grain Size of WC ( ⁇ m) Flank Wear (mm) 1-4 0.26 0.38 0.3 chipped in 3 min. 41 sec. 15-1 0.48 0.47 1.5 chipped in 2 min. 39 sec. 15-2 0.50 0.42 0.3 0.40 15-3 0.55 0.38 0.3 0.37 15-4 0.59 0.37 0.3 0.32 15-5 0.63 0.35 0.3 0.25
  • a sample No. 15-5 was prepared in the same composition as the sample No. 1-4 under conditions similar to those in Test Example 3 except that the mean grain size of WC was changed to 0.25 ⁇ m, with employment of an ultra high-pressure vessel, and subjected to X-ray diffraction.
  • samples Nos. 15-2, 15-3 and 15-4 were prepared from the same powder materials as the sample No. 15-1 in the method of Test Example 1 with a keeping time of 2 minutes while setting only the sintering temperatures at 1200°C, 1250°C and 1300°C respectively, and a sample No. 15-5 was prepared at a sintering temperature of 1300°C for a keeping time of 10 minutes, to be similarly subjected to X-ray diffraction.
  • Table 8 also shows the results of these samples, along with the mean grain sizes of WC in the respective samples.
  • the sintered bodies prepared in the aforementioned manner were worked into shapes of ISO No. RNGN120400 so that V and H surfaces defined rake faces and flanks respectively, and cutting edges were chamfered by 0.2 x - 25° for cutting granite workpieces under the following cutting conditions:
  • Table 8 also shows flank wear widths after working for 5 minutes. From the results shown in Table 8, it is understood that the samples Nos. 15-2, 15-3, 15-4 and 15-5 exhibited superior wear resistance to the sample 15-1 exhibiting no orientation to a specific direction.
  • Sintered bodies were prepared from raw powder materials of the same composition as the sample No. 1-1 of Test Example 1 under conditions similar to those in Test Example 1, except that the sintering was made at temperatures of 1000°C, 1100°C, 1200°C and 1300°C respectively. Rakes faces of these sintered bodies were lapped and presence/absence of pores in WC-Co phases was observed with an optical microscope of 200 magnifications. The results of the observation were classified in the range of A00 to B08 on the basis of ISO standards. Table 9 shows the results, along with transverse rupture strength of the respective sintered bodies.
  • Sintered bodies of samples Nos. 17-1, 17-5 and 17-10 were prepared to be 30 mm square with thicknesses of 5 mm by employing powder materials having the compositions of the samples Nos. 1-1, 1-3 and 1-5 shown in Table 1, feeding a current to a graphite mold in a vacuum of 0.005 Torr under 40 MPa so that the programming rate was 200°C/min., keeping the graphite mold at 1150°C for 1 minute for direct resistance heating and pressurized sintering, and then quenching the same.
  • 17-2 to 17-4, 17-6 to 17-9 and 17-11 were prepared by employing raw powder materials of the same compositions as the above while coating only diamond grains with metals such as Ir, Os, Pt, Re, Rh, Cr, Mo, W and the like by electroplating in thicknesses of about 5 ⁇ m.
  • the sample No. 17-7 had two coating layers consisting of outer and inner layers of W and Cr respectively on the diamond surface.
  • the sintered bodies prepared in the aforementioned manner were surface-ground with a grinding stone of #250, and sandblasted under pressure of 10 kg/cm 2 for 60 minutes, similarly to Test Example 2.
  • Table 10 shows the weight reduction ratios in this test.
  • Table 10 Sample No. Raw Material Composition Coating Layer ( ⁇ m) Weight Reduction Ratio (%) Transverse Rupture Strength (GPa) 17-1 No. 1 no 0.61 2.0 17-2 No. 1 Pt 2 0.36 2.3 17-3 No. 1 Rh 3 0.21 2.4 17-4 No. 1 Cr 5 0.28 2.2 17-5 No. 3 no 0.46 1.7 17-6 No. 3 Mo 10 0.35 1.9 outer layer inner layer 17-7 No. 3 W3 -Cr 2 0.31 2.0 17-8 No. 3 Re 2 0.23 2.3 17-9 No. 3 Ir 5 0.25 2.2 17-10 No. 5 no 0.23 1.4 17-11 No. 5 Os 3 0.11 1.8 17-12 No. 5 Ti 3 0.31 1.9 17-13 No. 5 Zr 5 0.28 1.5 17-14 No. 5 V 5 0.29 1.5
  • samples Nos. 17-12 to 17-14 were prepared by coating diamond grains with Ti and Zr. In each of these samples, however, wear resistance was reduced as compared with the sample No. 17-10 having no coating. It is conceivable that such performance difference in wear resistance between the different types of coated metals depends on whether or not diamond can be protected against attack by a liquid phase formed in the sintering step. In other words, it is conceivable that the coating metal forms a solid phase in formation of a liquid phase to be capable of preventing the diamond from coming into contact with the liquid phase.
  • Sintered bodies of samples Nos. 18-3 and 18-7 were prepared by forming Co and Ni coating layers of 10 ⁇ m and 20 ⁇ m in thickness between the sintered bodies of the samples Nos. 17-3 and 17-7 of Test Example 17, the diamond grains of these samples and outer coatings of Rh and W/Cr respectively by electroplating.
  • Table 11 shows Charpy impact values of these samples.
  • Table 11 Sample No. Charpy Impact Value (MPa ⁇ m) 17-3 0.051 17-7 0.062 18-3 0.064 18-7 0.077
  • the Charpy impact values were improved by forming the Co and Ni coating layers between the diamond grains and the outer coatings.
  • the inventive diamond-dispersed superhard composite member is deteriorated in impact strength as compared with a simple superhard member due to the dispersion of diamond, and readily chipped when the same is applied to a rock bit or the like, for example.
  • the impact strength can be improved by forming Co and Ni coating layers.
  • WC powder A of 5 ⁇ m in mean grain size
  • WC powder B of 2 ⁇ m in mean grain size
  • WC powder C of 0.5 ⁇ m in mean grain size
  • 20 vol.% of Co powder of 2 ⁇ m in mean grain size and 5 vol.% of diamond powder of 100 ⁇ m in mean grain size.
  • These powder materials were subjected to direct resistance heating and pressurized sintering at a programming rate of 100°C/min. and a sintering temperature of 1200°C for a keeping time of 1 minute, and thereafter quenched for obtaining sintered bodies of samples Nos. 19-1 to 19-6.
  • the Charpy impact values of the samples Nos. 19-3 to 19-6 having abundance ratios of WC grains having sizes larger than 3 ⁇ m in excess of 50 % were relatively higher than those of the remaining samples, and these samples are conceivably suitable for application requiring impact resistance. Further, it has been possible to confirm that the samples Nos. 19-5 and 19-6 having the abundance ratios of the WC grains having sizes smaller than 1 ⁇ m within the range of 10 to 35 % exhibited excellent values as to transverse rupture strength, and had excellent performance balance.
  • Sintered bodies of samples Nos. 20-1 to 20-9 were prepared under the same conditions as Test Example 19 except that the grain sizes of the WC and diamond powder materials were different. The diamond and Co contents were fixed at 30 vol.% and 15 vol.% respectively. These sintered bodies were subjected to a cutting test under cutting conditions similar to those in Test Example 15.
  • Table 13 shows abrasion loss values.
  • Table 13 Sample No. Mean Grain Size of WC ( ⁇ m) Mean Grain Size of Diamond ( ⁇ m) Flank Wear (mm) 20-1 5.6 50 0.48 20-2 2.6 50 0.33 20-3 0.8 50 0.15 20-4 5.6 8.5 0.41 20-5 2.6 8.5 0.22 20-6 0.8 8.5 0.13 20-7 5.6 2.7 0.38 20-8 2.6 2.7 0.15 20-9 0.8 2.7 0.09
  • the sintered bodies having WC mean grain sizes of not more than 3 ⁇ m, particularly not more than 1 ⁇ m, are superior in wear resistance, and the sintered bodies having diamond mean grain sizes of not more than 10 ⁇ m are further superior in wear resistance.
  • the mean grain sizes of WC and diamond are not more than 1 ⁇ m and not more than 10 ⁇ m respectively.
  • Samples Nos. 21-1 to 21-7 were prepared by partially or entirely replacing the diamond of the samples Nos. 1-1 to 1-7 with CBN or WBN of 5 ⁇ m or 10 ⁇ m in mean grain size under the same conditions, for forming sintered bodies of 20 mm in diameter and 5 mm in thickness.
  • Table 14 Sample No. CBN vol% WBN Diamond WC TiC Co Ni Rest 21-1 5 0 0 70 20 TaC 5 21-2 5 5 5 0 60 3 26 1 21-3 0 10 5 5 50 10 15 Mo 2 C 5 21-4 25 0 0 55 20 21-5 30 0 5 40 5 15 Cr 5 21-6 30 10 10 10 10 30 (Ti,Ta,W)C10 21-7 0 70 0 5 15 5 NbC 5
  • the sintered bodies of the aforementioned samples were subjected to a cutting test for sandstone workpieces under the following conditions, for measurement of abrasion loss values.
  • Table 16 shows times up to such chipping.
  • Table 16 also shows Charpy impact values.
  • the cutting conditions were a cutting speed of 100 m/min., a feed rate of 0.2 mm/rev., a depth of cut of 0.3 mm, a time of 5 minutes, and a dry type. From the results shown in Table 16, it is understood that the superhard composite members of the samples Nos.
  • 1-1, 1-2, 1-4, 1-5 and 1-6 each comprising a hard phase mainly composed of WC, a binder phase mainly composed of Co, and a plurality of diamond grains dispersed in a structure having the hard phase and the binder phase and satisfying all of the factors (1) the main crystal system of Co is f.c.c.; (2) the member has apparent porosity satisfying the range of A00 to A08 and B00 to B08 in ISO standards; (3) the content of the diamond grains is 5 to 50 vol.%; and (4) there are no parts where the diamond grains are directly bonded to each other have superior performance as compared with the samples Nos. 1-3, 1-7, 3-1, 4-1, 22-1 and 22-2 not satisfying the aforementioned conditions. Table 16 Sample No.
  • the inventive member can be applied to a mine civil engineering tool such as a casing bit, an earth auger bit, a shield cutter bit or the like, a cutting tool such as a tip for working wood, metal or resin, a bearing for a machine tool, a wear-resistant material such as a nozzle, a plastic working tool such as a wire drawing die, a grinding tool or the like.
  • the inventive method it is possible to obtain a dense superhard composite member which is excellent in hardness and wear resistance by performing sintering in a short time. Further, the temperature rising time, the keeping time and the cooling time can be shortened, whereby further cost reduction can be expected as compared with the prior art.

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WO2001032947A1 (fr) 1999-10-29 2001-05-10 Sumitomo Electric Industries, Ltd. Matiere composite contenant des particules ultra-dures
US6454027B1 (en) 2000-03-09 2002-09-24 Smith International, Inc. Polycrystalline diamond carbide composites
GB2362655A (en) * 2000-03-09 2001-11-28 Smith International Cermets containing polycrystalline diamond or cubic boron nitride
GB2362655B (en) * 2000-03-09 2004-09-15 Smith International Polycrystalline diamond carbide composites
WO2002006545A2 (fr) * 2000-07-13 2002-01-24 Kennametal Inc. Metal dur utilise dans des charges de tres haute durete et procede de fabrication associe
WO2002006545A3 (fr) * 2000-07-13 2002-05-30 Kennametal Inc Metal dur utilise dans des charges de tres haute durete et procede de fabrication associe
US7033408B2 (en) 2000-08-08 2006-04-25 Robert Fries Method of producing an abrasive product containing diamond
WO2002011876A3 (fr) * 2000-08-08 2002-07-25 De Beers Ind Diamond Procede de production d'un produit abrasif contenant du diamant
US6919040B2 (en) 2000-08-08 2005-07-19 Robert Fries Method of producing an abrasive product containing cubic boron nitride
CN1295368C (zh) * 2000-08-08 2007-01-17 六号元素(控股)公司 制备包含金刚石的研磨产品的方法
WO2002011876A2 (fr) * 2000-08-08 2002-02-14 Element Six (Pty) Ltd. Procede de production d'un produit abrasif contenant du diamant
WO2002020863A1 (fr) * 2000-09-06 2002-03-14 Nederlandse Organisatie Voor Toegepast-Natuur-Wetenschappelijk Onderzoek Tno Corps en metal dur a gradient de durete, tels des outils de poinçonnage
NL1016112C2 (nl) * 2000-09-06 2002-03-07 Tno Lichaam van gradueel hardmetaal zoals stansgereedschap en werkwijze voor het produceren daarvan.
EP1545870A2 (fr) * 2002-08-01 2005-06-29 Steven G. Smarsh Composant de machine de meulage resistant a l'usure
EP1545870A4 (fr) * 2002-08-01 2007-07-18 Steven G Smarsh Composant de machine de meulage resistant a l'usure
US7392865B2 (en) 2003-12-02 2008-07-01 Smith International, Inc. Randomly-oriented composite constructions
US7243744B2 (en) 2003-12-02 2007-07-17 Smith International, Inc. Randomly-oriented composite constructions
EP1674177A1 (fr) * 2004-12-21 2006-06-28 Dr. Fritsch Sondermaschinen GmbH Dispositif de frittage sous pression
US7441610B2 (en) 2005-02-25 2008-10-28 Smith International, Inc. Ultrahard composite constructions
US7757788B2 (en) 2005-02-25 2010-07-20 Smith International, Inc. Ultrahard composite constructions
US8679206B2 (en) 2007-01-26 2014-03-25 Diamond Innovations, Inc. Graded drilling cutters
WO2008092093A2 (fr) * 2007-01-26 2008-07-31 Diamond Innovations, Inc. Lames de forage calibrées
WO2008092093A3 (fr) * 2007-01-26 2008-09-12 Diamond Innovations Inc Lames de forage calibrées
US8790439B2 (en) 2008-06-02 2014-07-29 Kennametal Inc. Composite sintered powder metal articles
WO2010029518A1 (fr) * 2008-09-15 2010-03-18 Element Six Holding Gmbh Métal dur
US8535407B2 (en) 2008-09-15 2013-09-17 Element Six Gmbh Hard-metal
CN102165081B (zh) * 2008-09-15 2014-05-14 六号元素控股有限公司 硬质合金
DE102009014521A1 (de) * 2009-03-13 2010-09-16 Dr. Fritsch Sondermaschinen Gmbh Drucksintervorrichtung mit einer Werkzeugform
EP2433727A1 (fr) 2010-09-24 2012-03-28 Sandvik Intellectual Property AB Procédé de production d'un corps composite fritté
WO2012038529A2 (fr) 2010-09-24 2012-03-29 Sandvik Intellectual Property Ab Procédé de production d'un corps composite fritté
WO2014018235A3 (fr) * 2012-07-26 2014-03-20 TDY Industries, LLC Articles de métal pulvérulent fritté composite
CN104073665A (zh) * 2014-06-26 2014-10-01 东北大学 一种WC-Co-cBN复合材料的制备方法
CN104073665B (zh) * 2014-06-26 2016-05-11 东北大学 一种WC-Co-cBN复合材料的制备方法
CN115283671A (zh) * 2022-08-11 2022-11-04 中科粉研(河南)超硬材料有限公司 一种CuNiSn合金-镀钛金刚石磨具复合材料及其制备方法和应用
CN115283671B (zh) * 2022-08-11 2023-09-29 中科粉研(河南)超硬材料有限公司 一种CuNiSn合金-镀钛金刚石磨具复合材料及其制备方法和应用

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Publication number Publication date
KR100219930B1 (ko) 1999-09-01
DE69621564D1 (de) 2002-07-11
EP1028171B1 (fr) 2003-03-26
DE69627053T2 (de) 2003-09-25
EP0774527A3 (fr) 1998-06-17
DE69627053D1 (de) 2003-04-30
KR970027339A (ko) 1997-06-24
JPH09194978A (ja) 1997-07-29
EP0774527B1 (fr) 2002-06-05
DE69621564T2 (de) 2003-01-09
JP3309897B2 (ja) 2002-07-29
US5889219A (en) 1999-03-30
EP1028171A1 (fr) 2000-08-16

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